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Aerospace Aluminium


Case Study: Thick Material Profiling


Client Sector: Aerospace


Material: 178mm thk Aircraft Grade Aluminium



Requirement:

To profile a billet 178mm square   -  1100mm long, with longitudinal cuts, to produce two blanks for final machining. 

  
 Final piece ready for CNC machiningWaterjet profiled material providing two final stock pieces 

Background:

Previously one billet was required to produce each finished component. With the advantages of ultra pressure waterjet cutting and the use of a Dynamic® cutting  head, it  is possible  to cut  the  billet in such a manner that two, oversized, blanks could be produced, suitable for final  machining.

Trial:

A test cut was conducted in the material to establish the ‘uncorrected’ cut taper. Over the depth of cut of 178mm - an ‘uncorrected’ taper of just 0.67mm was observed. This is removed completely  by applying a  corrective  factor within the  software that controls the Dynamic® cutting head. 



Cut 1

The first cut ( full thickness of  178mm) removes material above the red line - instead of being swarf  it is now
valuable material available for smaller parts. 

Cut 2

The stock from cut 1 is rotated 90 degrees and a second cut (common cut) is completed. Manipulation of the
cutting programme compensates for the varying thickness of cut, from full  thickness of 178mm down to 83mm 
at its thinnest.

Result:

  1. Material yield doubled
  2. Material offcuts - formerly waste swarf - are now useable for the manufacture of other components

If you have a 'problem' like this, talk to the 'problem solvers' at Hydromar.



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